Pressurized Structures Responsible Engineer

CrosslinkedJobs/Composites/Pressurized Structures Responsible EngineerFSPressurized Structures Responsible EngineerFrontera Space Austin, TXtodayverified 2 h agoOwn design, analysis, materials, manufacturing, and testing of pressurized composite structures for a space vehicle.ApplyApplySeniority SeniorWork On-siteType Full-timeDegree BSExperience 4+ yrsIndustry AerospaceRole R&D / ResearchSchedule StandardMaterialscomposites467thermoset resins6cryogenic materials2liner materialstoughenersadhesives239Techniquesstructural analysis26FEA113fracture mechanics7cryogenic testing3Mode I/II fracture testingcure kinetics analysis1Role detailsOverviewFrontera Space is developing a next-generation space transportation vehicle and is seeking a Responsible Engineer (RE) to own its pressurized composite structural systems.The Pressurized Composite Structures RE will be the technical owner and primary point of accountability for the architecture, design, analysis, materials, manufacturing, testing, and qualification of the vehicle’s pressurized and cryogenic composite structures.This is a hands-on technical leadership position. The RE will establish the structural architecture, make fundamental materials and design decisions, build and lead the pressurized structures team, and maintain end-to-end technical integrity from early development through flight.The ideal candidate combines deep experience in composite pressure structures and cryogenics with a fundamental understanding of polymer and composite behavior, including cure kinetics, residual stresses, microcracking, fracture mechanics, permeability, and durability under combined pressure and thermal cycling.This is a full-time, exempt, in-person position reporting to the COO and Interim Director of Structures in the Austin, Texas area.What You’ll DoServe as the Responsible Engineer and technical authority for pressurized composite structures on Frontera’s next-generation space transportation vehicle.Architect composite pressure vessels, propellant and cryogenic tanks, domes, barrels, joints, penetrations, interfaces, and supporting structures.Own requirements, structural architecture, sizing, detailed design, analysis, manufacturing development, testing, qualification, and flight implementation.Establish material systems, laminate architectures, load paths, joints, interfaces, and manufacturing approaches.Lead development of pressure structures subjected to internal pressure, vehicle loads, cryogenic environments, thermal gradients, pressure and cryogenic cycling, and manufacturing/cure-induced residual stresses.Understand and control composite durability mechanisms including microcracking, delamination, fiber/matrix behavior, Mode I/II fracture, thermal-expansion mismatch, cure shrinkage, permeability/leak paths, fatigue, and accumulated damage.Apply thermoset cure kinetics and process-property relationships to material selection and manufacturing process definition.Define resin, fiber, adhesive, liner, coating, toughener, and joining-system requirements for cryogenic pressure structures.Perform and/or direct structural analysis including laminate stresses and margins, pressure loading, combined mechanical/thermal loading, buckling, fracture mechanics, damage tolerance, fatigue, pressure-cycle life, proof/burst capability, and residual/thermal stresses.Develop material characterization and structural verification programs spanning coupons, elements, subcomponents, development articles, and full-scale tanks.Define and execute proof, burst, pressure-cycle, cryogenic-cycle, fracture, permeability, and qualification testing.Correlate analytical models with test results and use test data to mature designs and material models.Work directly with manufacturing engineers and technicians to establish robust, repeatable composite fabrication and assembly processes.Establish design allowables, structural margins, factors of safety, acceptance criteria, inspection requirements, and verification methodologies.Lead design and technical reviews and own disposition of structural nonconformances, manufacturing deviations, and test anomalies.Partner with propulsion, fluids, thermal, vehicle structures, manufacturing, test, and systems engineering.Recruit, mentor, and lead the pressurized composite structures engineering team.Establish tools, analysis methods, standards, and engineering practices for rapid development of flight-critical pressure hardware.Drive designs toward minimum mass, structural efficiency, manufacturability, durability, rapid production, and operational reliability.What Success Looks LikeYou become the technical owner of the pressurized composite structural architecture for Frontera’s next-generation space transportation vehicle.You establish a technically rigorous approach to designing large, lightweight composite pressure structures capable of operating reliably through demanding pressure, mechanical, and cryogenic environments.You build and lead a highly capable engineering team while remaining directly involved in the critical structural, materials, manufacturing, and test decisions.You lead the system from material and process development through component testing, full-scale qualification, and ultimately flight-ready hardware.Employment DetailsFull-time, exempt positionPrimarily in-person in the Austin, Texas areaRegular interaction with engineering, manufacturing, and test teamsTravel to suppliers, manufacturing facilities, and test locations may be requiredHands-on participation in hardware development and testing is expectedQualifications*What We’re Looking For (Requirements)*Bachelor’s degree in Aerospace, Mechanical, Materials, Polymer Engineering, or a related technical discipline.4+ years of professional experience directly developing pressurized composite aerospace structures.Demonstrated experience with composite pressure vessels, cryogenic/propellant tanks, COPVs, pressurized aerospace structures, or comparable flight-critical hardware.Strong understanding of composite mechanics, laminate theory, structural analysis, and composite failure mechanisms.Strong understanding of cryogenic materials and structural behavior.Fundamental understanding of thermoset cure kinetics, cure shrinkage, residual stresses, microcracking, delamination, fracture mechanics/durability, fatigue, thermal stresses, and permeability.Experience with structural proof, qualification, or development testing of pressure hardware.Experience working directly with composite manufacturing and flight or production hardware.Ability to independently make and defend critical technical decisions for flight-critical structures.Demonstrated ability to lead multidisciplinary engineering efforts and develop other engineers.*Bonus Points (Preferred)*10+ years developing pressurized composite aerospace structures.Experience as a Responsible Engineer, Principal Engineer, Lead Engineer, or equivalent technical authority for a pressure vessel, cryogenic tank, or major flight structural system.Experience architecting a clean-sheet pressurized structural system from concept through qualification and flight.Experience building and leading an engineering team responsible for a major vehicle subsystem.Deep expertise in cryogenic composite structures, particularly liquid hydrogen and/or liquid oxygen service.Experience developing large-scale, linerless, or thin-lined composite cryogenic pressure structures.Deep understanding of relationships among resin chemistry, cure kinetics/cycles, glass-transition behavior, thermal expansion, residual stresses, microcracking, fracture toughness, and permeability.Experience characterizing or improving Mode I/II fracture toughness.Experience with repeated cryogenic thermal and pressure cycling.Experience developing customized or highly optimized resin systems.Experience with AFP/ATL, filament winding, prepreg layup, resin infusion, bonded structures, or automated composite manufacturing.Experience developing test programs from material coupons through full-scale structural qualification.Experience with launch vehicles, spacecraft, reusable space vehicles, hypersonic vehicles, missiles, or other high-performance aerospace systems.Technical SkillsComposite laminate design and analysis; composite failure criteria and damage mechanics; cryogenic structural and pressure-vessel analysis; fracture mechanics and damage tolerance; Mode I/II fracture behavior; polymer and thermoset cure kinetics; residual and thermal stress analysis; microcracking and permeability; composite fatigue and durability; finite element analysis; material characterization and test correlation; structural proof/burst and cryogenic qualification testing; composite manufacturing; structural test planning; engineering requirements and verification; and technical authority.Working ConditionsThis role operates in a fast-paced aerospace development environment spanning engineering, manufacturing, integration, and testing. Work may involve large composite structures, pressure and cryogenic systems, test equipment, manufacturing machinery, and flight hardware.The successful candidate must be comfortable moving between fundamental materials science, detailed engineering analysis, hardware manufacturing, and hands-on structural testing.Export Control EligibilityCertain positions supported by this role may involve work subject to U.S. export-control laws and regulations. Candidates for those roles may be required to meet applicable U.S. export-control eligibility requirements.Equal Opportunity EmployerFrontera Space is an equal opportunity employer. We are committed to providing a workplace free from discrimination and harassment and consider applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, genetic informationWhy Join Us?You will have the opportunity to influence the vehicle architecture, solve foundational technical challenges, and see your work move rapidly from analysis and design into hardware, testing, and flight. As an early team member, you will take on broad ownership, help establish the engineering culture, and directly shape both the product and the company.ConnectedAll roles at Frontera SpaceMore R&D / Research rolesRoles using structural analysisComposites,Thermosets,Coatings/films rolesRelated rolesCF R&D Technician - Second ShiftCommonwealth Fusion Systems Devens, MA LM Senior Supplier Industrialization Engineer, InteriorsLucid Motors Southfield, MI FS Airframe Structures Responsible EngineerFrontera Space Austin, TX AC Manufacturing Engineer 3Applied Composites Los Alamitos, CA GB Product Development EngineerGreen Bay Packaging Green Bay, WI Common questionsWhere is the Pressurized Structures Responsible Engineer role at Frontera Space based?This role is based in Austin, TX.What degree is required for the Pressurized Structures Responsible Engineer role at Frontera Space?This role requires a BS.How many years of experience does this Pressurized Structures Responsible Engineer role require?The posting calls for at least 4 years of relevant experience.What polymers or materials does this Pressurized Structures Responsible Engineer role work with?composites, thermoset resins, cryogenic materials.What techniques or methods are required for this Pressurized Structures Responsible Engineer role?structural analysis, FEA, fracture mechanics, cryogenic testing.